Abstract: The present invention relates to fire retardant compositions, and fire retardant objects formed therefrom comprising a preformed gas-producing material and a matrix, wherein, in use, the gas-producing material prevents, limits or reduces combustion of the matrix. Also disclosed are methods of producing fire retardant compositions, methods of making objects formed therefrom as well as structures having fire retardant properties.

Abstract: The present invention relates to gas-producing materials, methods of forming gas-producing materials, and uses of gas-producing materials. The gas-producing materials comprise a comminuted foamed polymer, a nitrogen-containing fuel and an oxidiser. The gas-producing materials may be used to suppress a fire.

Abstract: The present invention relates to methods of manufacturing composite products having a surface effect. In some examples described, a composite product has a simulated surface, for example a stone-effect surface formed by pressing a particulate-form surface material (30) and a sheet-form curable material (40) onto a substrate (44) having an open-celled structure. In other examples, a laminate product having a veneer is formed by pressing a veneer and a sheet-form material onto a substrate including a porous structure. The veneer may comprise a wood material. In other examples, a surface effect material is bonded to a skin by pressing a sheet-form curable material to a mold surface and the surface effect material. Where the surface effect material has a high thermal conductivity, the composite product formed can feel cool to the touch.

Abstract: A helmet (10) comprising (i) an outer shell (12); (ii) an inner pad (14) configured to deform resiliently to cushion the head of a user; and (iii) a solid open-cell foam material (18) wherein the outer shell is spaced apart from the inner pad by the solid open-cell foam material and wherein the solid open-cell foam material is arranged to deform irreversibly in the event of an impact which applies a pressure greater than a selected threshold pressure to absorb the energy of the impact.

Abstract: A method comprises a) attaching a first skin to a first surface of an open cell foam to form a precursor for a door, window or panel; and b) attaching a second skin to the precursor in a separate step from step a). A precursor for a door, window, or panel, comprises a skin attached to one face of an open cell foam, but not to an opposing face of the open cell foam.

Abstract: The present invention relates to composite materials and the use thereof as energy resistant, for example blast-resistant, materials. Preferred aspects of the invention relate to layered composite panels comprising solid foam materials which have both a blast attenuation function and an anti-ballistic function. In further aspects, the invention provides novel composite panels which are suitable for use as blast resistant and/or anti-ballistic materials. In some examples described, the layered composite panel comprises a polymeric material (10) bonded to a first solid open-cell foam panel (12), and a cured polymeric material (14) penetrates a surface of the first solid open-cell foam panel (12).

Abstract: The present invention relates to methods of manufacturing composite products having a surface effect. In some examples described, a composite product has a simulated surface, for example a stone-effect surface formed by pressing a particulate-form surface material (30) and a sheet-form curable material (40) onto a substrate (44) having an open-celled structure. In other examples, a laminate product having a veneer is formed by pressing a veneer and a sheet-form material onto a substrate including a porous structure. The veneer may comprise a wood material. In other examples, a surface effect material is bonded to a skin by pressing a sheet-form curable material to a mould surface and the surface effect material. Where the surface effect material has a high thermal conductivity, the composite product formed can feel cool to the touch.

Abstract: The present invention relates to methods for forming a composite product having a patterned surface. A substrate including a porous structure (136), a sheet-form material (134) and a patterned sheet (131) are pressed together to form the composite product. In preferred examples, the patterned sheet is permeable to curable material in the sheet-form material.

Abstract: A method of forming a composite product is described. An example of the method comprises providing a layer (34) comprising a sheet-form moulding material and providing a substrate (36). The layer of sheet-form material is applied onto a surface of the substrate (36); and pressed to the substrate in a mould (30). In some examples, the substrate (36) is an open celled foam and gas and/or vapour can be displaced from the pressing region.

Abstract: A process for the manufacture of a glazable, molded panel, door or window which molding includes, on at least three sides of the area to be glazed, a plastics foam core and one or more continuous, integral skins comprising a synthetic polymer, which process includes: forming the plastics foam core with a continuous groove in register with the intended position of the glazing, the groove extending along the at least three sides of the area to be glazed; lining the groove with a layer of a synthetic polymer which may be the same as or different from the skin polymer(s), the layer being at least partly contiguous with the or each skin; slidably inserting a former into the groove; and molding the panel, door or window with the application of heat and pressure thereby bonding the layer of synthetic polymer to the or each skin to form a continuous, integral skin of a synthetic polymer about the at least three sides of the area to be glazed.

Abstract: A method comprises a) attaching a first skin to a first surface of an open cell foam to form a precursor for a door, window or panel; and b) attaching a second skin to the precursor in a separate step from step a). A precursor for a door, window, or panel, comprises a skin attached to one face of an open cell foam, but not to an opposing face of the open cell foam.

Abstract: A process for the manufacture of a glazable, moulded panel, door or window which moulding includes, on at least three sides of the area to be glazed, a plastics foam core and one or more continuous, integral skins comprising a synthetic polymer, which process includes: forming the plastics foam core with a continuous groove in register with the intended position of the glazing, the groove extending along the at least three sides of the area to be glazed; lining the groove with a layer of a synthetic polymer which may be the same as or different from the skin polymer(s), the layer being at least partly contiguous with the or each skin; slidably inserting a former into the groove; and moulding the panel, door or window with the application of heat and pressure thereby bonding the layer of synthetic polymer to the or each skin to form a continuous, integral skin of a synthetic polymer about the at least three sides of the area to be glazed.

Abstract: The use is described of rigid foam cores in panels, especially doors, of the kind comprising a foam core (22) between two molded skins (8,10). The weather-resistance, especially the resistance to thermally-induced bowing, of such panels is improved by forming the panel of at least one vacuum-formed thermoplastics skin (8,10) adhesively bonded to a substantially open-cell, rigid foam core (22). If the foam has frangible cell walls, it can be conformed to accommodate the depressed zones of a molded overlying door skin (8,10) by crumbling under compression, with fracture of the cell walls to accommodate the zones. A preferred open-cell rigid foam is a phenolic foam reinforced with finely divided particulate filler.

Abstract: Synthetic resin mouldings such as panels and doors having an improved simulated wood grain finish are obtained by first coating a part of all of the mold surface with at least one colorant having a color which is different from the color of the resin cured and then wiping the mold surface. This has the unexpected effect of concentrating the colorant on the peaks and high points of the moulding and thus in the valleys of the resultant moulding.

Abstract: A method of shaping a body, suitable for use in the building or furnishing industry, including: engaging a surface region of the body with a tool having a predetermined profile; effecting relative movement between the body and the tool in a direction generally parallel with a surface of said region, the body being formed of a material which is sufficiently friable as it is engaged by the tool during the relative movement to be removed but sufficiently rigid for adjacent material to remain attached, whereby said surface region is formed with a recess having a profile corresponding to the predetermined profile of the tool. The method is particularly suitable for profiling of plaster materials and rigid plastic foams such as phenolic foams.

Abstract: Foam laminates wherein the bond between the foam layer and the adjacent layer is enhanced by mechanical keying, which exhibit excellent surface finishes and are suitable in a wide variety of uses are obtained very simply in a single step and without the need for complicated molding equipment or expensive mold materials by a method comprising:(i) providing a solid body of foamed material comprising foamed synthetic resin with or without a filler, said body containing substantially an open-cell structure and having a face containing pores open to the surface;(ii) applying to or forming on said face a layer of viscous or pasty settable material;(iii) applying pressure to the layer to force some of the material to enter into at least some of said pores while in the unset state and simultaneously to mold the external surface of the layer; and thereafter(iv) causing or allowing said settable material to set whereby to form a foam laminate including a layer of set material which is mechanically keyed to said solid b

Abstract: Foamed resinous products having excellent fire resistance, high thermal insulation and good resistance to heat are obtained at temperatures as low as room temperature and without the need for an added blowing agent by forming a mixture of a phenolic resole having a specified reactivity, an acid hardener for the resole and, uniformly dispersed through the mixture of resole and hardener, at least 20% by weight of a finely divided inert and insoluble particulate solid; products capable of being employed as wood-substitutes are obtained when a dihydric compound is included in the mixture and the solid is talc, fly ash and/or a hydraulic cement.

Abstract: Foamed resinous products having excellent fire resistance, high thermal insulation and good resistance to heat are obtained at temperatures as low as room temperature and without the need for an added blowing agent by forming a mixture of a phenolic resole having a specified reactivity, an acid hardener for the resole and, uniformly dispersed through the mixture of resole and hardener, at least 20% by weight of a finely divided inert and insoluble particulate solid; products capable of being employed as wood-substitutes are obtained when a dihydric compound is included in the mixture and the solid is talc, fly ash and/or a hydraulic cement.